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Abstract:

Various embodiments relate to a pressure sensor and related methods of
manufacturing and use. A pressure sensor may include an electrical
contact included in a flexible membrane that deflects in response to a
measured ambient pressure. The electrical contact may be separated from a
signal path through a cavity formed using a sacrificial layer and PVD
plugs. At one or more defined touch-point pressure thresholds, the
membrane of the pressure sensor may deflect so that the state of contact
between an electrical contact and one or more sections of a signal path
may change. In some embodiments, the change of state may cause the
pressure sensor to trigger an alarm in the electrical circuit. Various
embodiments also enable the operation of the electrical circuit for
testing and calibration through the use of one or more actuation
electrode layers.

Claims:

1. A pressure sensor comprising: a substrate including a first metallic
contact; a membrane attached to the substrate, the membrane including a
second metallic contact and responding to pressure by deflection; a
cavity wherein the first and second metallic contacts are located; a
contact area between the first and second metallic contacts that enables
contact between the first and second contacts when the membrane deflects
at a defined pressure; and a signal path that allows a current flow when
the first metallic contact makes contact with the second metallic
contact.

2. The pressure sensor of claim 1, wherein one of the first or second
metallic contacts further comprises an interconnect including the contact
area that makes contact with the other metallic contact when the membrane
is deflected through the height of the cavity.

3. The pressure sensor of claim 2, wherein: the interconnect further
comprises a second contact area, and the signal path comprises two
separate portions on one of the substrate or the membrane, wherein the
interconnect makes contact with the two portions of the signal path when
the membrane is deflected through the height of the cavity.

4. The pressure sensor of claim 1, wherein the first metallic contact
initially does not make contact with the second metallic contact, and
further wherein the first metallic contact makes contact with the second
metallic contact when the pressure exceeds the defined pressure.

5. The pressure sensor of claim 1, wherein the first metallic contact
initially makes contact with the second metallic contact, and further
wherein the first metallic contact breaks contact with the second
metallic contact when the pressure exceeds the defined pressure.

6. The pressure sensor of claim 5, further comprising: a lever that
causes the first metallic contact to break contact with the second
metallic contact when the membrane deflects through the height of the
cavity.

7. The pressure sensor of claim 4, further comprising: a series of
metallic contact pairs, each metallic contact pair comprising: a membrane
metallic contact, and a substrate metallic contact, wherein each metallic
contact pair makes contact when the membrane deflects at distinct
pressures.

8. The pressure sensor of claim 1, further comprising: a first actuation
electrode layer on the substrate; and a second actuation electrode layer
on the membrane.

9. The pressure sensor of claim 8, further comprising: a
pressure-actuated switch that deflects the pressure-sensitive membrane in
response to an applied electric potential difference between the first
and second actuation electrode layers.

10. The pressure sensor of claim 8, further comprising: a pressure
indicator that measures an applied pressure based on a capacitive
measurement between the first and second actuation electrode layers.

11. The pressure sensor of claim 8, further comprising: a user-controlled
system that applies an electric potential difference between the first
and second actuation electrode layers until the first and second metallic
contacts make contact.

12. The pressure sensor of claim 8, further comprising: a transistor
whose state is based on contact between the first and second metallic
contacts.

13. The pressure sensor of claim 12, wherein the transistor is connected
to an electrical circuit, and further wherein current flow in the
electrical circuit is based on the state of the transistor.

14. The pressure sensor of claim 13, wherein active current flow in the
electrical circuit triggers an alarm.

15. The pressure sensor of claim 8, further comprising: a configuration
system that: applies an electric potential difference between the first
and second actuation electrode layers to deflect the membrane; detects a
change in capacitance after the deflection of the membrane; compares the
detected change in capacitance to stored calibration data; and applies a
correction voltage between the first and second actuation electrode
layers to deflect the membrane to a corrective position.

16. The pressure sensor of claim 1, wherein the cavity is sealed during
manufacture and further wherein a cavity pressure inside the cavity is a
vacuum or is less than the defined pressure.

17. The pressure sensor of claim 16, further comprising: a metallic plug
that seals the cavity, comprising at least one of Al, Ti, TiW, W, Ta,
TaN, or Cu.

18. The pressure sensor of claim 1, wherein the metallic contacts
comprise one of: a noble metal from the group of Au, Ag, Pt, Pd, Ru, Os,
Ir, or Rh; an alloy of the noble metals; or an alloy of the noble metal
with a refractory metals from the group of Al, Ti, Zr, Hf, Ta, Nb, V, W,
Mo, Cr, Co, Mn, Cu, or Ni.

19. A method comprising: providing, by a substrate, a first metallic
contact; measuring, by a pressure sensor having a membrane including a
second metallic contact, a defined pressure; deflecting, by the membrane
in response to the defined pressure, through a height of a cavity to the
substrate; making, by the second metallic contact, contact with the first
metallic contact when the membrane deflects at the defined pressure; and
conducting, by a signal path, a current flow when the first metallic
contact makes contact with the second contact.

20. A method of producing a pressure sensor comprising: depositing and
patterning a first metallic layer on a substrate; depositing and
patterning a sacrificial layer upon the first metallic layer and
substrate; depositing and patterning a second metallic layer on the
sacrificial layer; etching a hole to the sacrificial layer; removing the
sacrificial layer; and plugging the etched hole with a plug.

21. The method of claim 20, further comprising: depositing a membrane
layer upon the sacrificial layer and first metallic layer, wherein the
second metallic layer is deposited and patterned on the membrane layer.

Description:

[0002] Various engineered systems use pressure sensors with linear outputs
to track changes in operation before such operational conditions become
critical. These pressure sensors may also include pressure switches that
trigger quick reaction in response to a measured critical condition.
Silicon-based pressure sensors and/or switches, such as sensors using
microelectromechanical system (MEMS) technology, have recently been used
for detection of pressure, especially in systems that also include
electrical circuits. Such MEMS pressure sensors usually include
piezo-resistive or capacitative components to measure ambient pressure in
non-critical conditions.

[0003] MEMS switches include components like deflecting beams or
cantilevers that make galvanic contact with each other. Similarly, some
MEMS switches include beam-suspended, perforated plates that change an
attached electrical circuit's impedance capacitatively. However, both
types of these existing MEMS switches require perfect sealing from the
environment to avoid degradation, such as contact degradation. Such
requirements impose severe restraints on the packaging of such switches.

[0004] In addition, certain applications require immediate action when a
critical pressure threshold is reached. However, many mechanical safety
measures (e.g., mechanical vanes, etc.) used to respond to such measured
pressures may not allow electrical or electronic control. Similarly,
electronic sensors may require constant power to operate correctly and
may still exhibit a more delayed response when compared to like
mechanical sensors.

SUMMARY

[0005] Provided are embodiments that enable a pressure sensor and a
pressure-actuated switch that may measure linear pressure changes and is
responsive to critical pressure levels. In particular, various
embodiments enable a pressure sensor that may control a current flow in
an electronic circuit, enabling alarms and other responses to pressure
measurements.

[0006] A brief summary of various exemplary embodiments is presented. Some
simplifications and omissions may be made in the following summary, which
is intended to highlight and introduce some aspects of the various
exemplary embodiments, but not to limit the scope of the invention.
Detailed descriptions of a preferred exemplary embodiment adequate to
allow those of ordinary skill in the art to make and use the inventive
concepts will follow in the later sections.

[0007] Various embodiments may relate to a pressure sensor comprising a
substrate including a first metallic contact, a membrane attached to the
substrate that includes a second metallic contact and responds to
pressure by deflection, and a cavity wherein the first and second
metallic contacts are located. The pressure sensor may also comprise a
contact area between the first and second metallic contacts that enables
contact between the first and second contacts when the membrane deflects
at a defined pressure and a signal path that allows a current flow when
the first metallic contact makes contact with the second metallic
contact. Some embodiments of the pressure sensor may also comprise a
first actuation electrode layer on the substrate and a second actuation
electrode layer on the membrane.

[0008] Various embodiments may also relate to a method comprising
providing, by a substrate, a first metallic contact, and measuring, by a
pressure sensor having a membrane including a second metallic contact, a
defined pressure. The method may also comprise deflecting, by the
membrane in response to the defined pressure, through a height of a
cavity to the substrate, making, by the second metallic contact, contact
with the first metallic contact when the membrane deflects at the defined
pressure; and conducting, by a signal path, a current flow when the first
metallic contact makes contact with the second contact.

[0009] Various embodiments may also relate to a method of producing a
pressure sensor comprising depositing and patterning a first metallic
layer on a substrate, depositing and patterning a sacrificial layer upon
the first metallic layer and substrate, and depositing and patterning a
second metallic layer on the sacrificial layer. The method may also
comprise etching a hole to the sacrificial layer, removing the
sacrificial layer, and plugging the etched hole with a plug.

[0010] It should be apparent that, in this manner, various exemplary
embodiments enable a pressure sensor and pressure-actuated switch.
Particularly, by providing a pressure sensor and a pressure-actuated
switch, a pressure sensor that may measure ambient pressures may also be
responsive to critical pressures.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] In order to better understand various exemplary embodiments,
reference is made to the accompanying drawings wherein:

[0012] FIGS. 1A-1C illustrate an exemplary pressure sensor and various
cross-sections of the exemplary pressure sensor;

[0013] FIGS. 1D-1F illustrate another exemplary pressure sensor and
pressure-actuated switch using an actuation electrode layer, with
cross-sections of the exemplary pressure sensor and switch;

[0014] FIGS. 1G-1I illustrate another exemplary pressure sensor and
pressure-actuated switch using an actuation electrode layer, with
cross-sections of the exemplary pressure sensor and switch;

[0015] FIGS. 2A-2C illustrate another exemplary pressure sensor and
pressure-actuated switch using a signal path through the membrane, with
cross-sections of the exemplary pressure sensor and switch;

[0016] FIGS. 2D-2F illustrate another exemplary pressure sensor and
pressure-actuated switch using a dimple on the bottom signal path, with
cross-sections of the exemplary pressure sensor and switch;

[0017] FIGS. 2G-2I illustrate another exemplary pressure sensor and
pressure-actuated switch using an actuation electrode layer with an
electrical contact, with cross-sections of the exemplary pressure sensor
and switch;

[0023] Referring now to the drawings, in which like numerals refer to like
components or steps, there are disclosed broad aspects of various
exemplary embodiments.

[0024] FIGS. 1A-1C illustrate an exemplary pressure and various
cross-sections of the exemplary pressure sensor. FIG. 1A illustrates a
top view of the pressure sensor 100, while FIG. 1B illustrates the
pressure sensor 100 along the 110 cross-section, and FIG. 1c illustrates
the pressure sensor 100 along the 120 cross-section. Pressure sensor 100
may comprise a membrane 103, a substrate 105, a signal path 107, and an
electrical contact 109. As shown in FIGS. 1B-1C, the pressure sensor 100
may include a cavity 113 between the membrane 103 and the substrate 105.
In some embodiments, the pressure sensor 100 may include a signal path
107, and one or more electrical contacts 109 that may be connected with
each other in certain pressure ranges; in such instances a signal or
current flow may traverse through the signal path 107 and the electrical
contact 109. In some embodiments, the contact between the signal path 107
and the electrical contact 109 may trigger an alarm or a similar response
in an electrical circuit that responds to the signal or current flow.

[0025] Substrate 105 may comprise a physical vapor deposition (PVD)
material that may enable contact with other components, such as
electrical connections to an external electrical circuit. As will be
discussed in further detail in relation to FIGS. 6A-6L, the outer layer
105 may have a composition of a PVD material. In some embodiments, the
substrate 105 may have a standard CMOS substrate composition, with a
finite number of metal layers deposited as a back-end-of-line (BEOL)
interconnect material. Membrane 103 may be attached at the sides to the
sides of the substrate 105. In such instances, the sides of the membrane
103 may remain relatively fixed, while portions farther away from the
substrate may move parallel to the sides, deflecting through the height
of the cavity 113.

[0026] Signal path 107 may include one or more pieces of conductive
material that may be used to form an electrical circuit. In some
embodiments, the composition of the signal path 107 may include a
non-corrosive, non-oxidative material, such as gold, platinum, or similar
noble materials. In some embodiments, the composition of the signal path
107 may include refractory materials that may be chosen based on
availability during manufacture. As illustrated in FIG. 1c, when the
electrical contact 109 makes galvanic contact with portions of the signal
path 107, an electrical signal in the electrical circuit may be allowed
to flow through both the electrical contact 109 and the signal path 107.

[0027] Electrical contact 109 may be one or more contacts positioned
within the membrane 103 or the substrate 109 that may make contact with
one or more portions of the signal path 107 at a defined pressure or
within a defined pressure range. Electrical contact 109 may be made of
the same conductive material as the signal path and may include one or
more interconnect dimples that may enable contact with one or more
portions of a signal path 107 when the membrane 103 experiences a
deflection equal to the height of the cavity 113. FIG. 1c illustrates an
exemplary electrical contact 109 included in the membrane 103 that
comprises two interconnect dimples that enable contact with separate
sections of the signal path 107 when the membrane deflects through the
height of the cavity 113. In the illustrative embodiment, the two dimples
in the electrical contact 109 form a bridge with the portions of the
signal path by making contact, such as galvanic contact, to close the
electrical circuit. This may occur when the membrane deflects at a
touch-point pressure. When the measured ambient pressure is equal to or
above the touch-point pressure, the electrical contact 109 may maintain
such galvanic contact with the signal path 107. In this embodiment, the
contact may be direct, coupled, or galvanic such that direct current may
flow through the signal path 107.

[0028] Membrane 103 may be a flexible membrane that may deflect a
specified deflection distance in response to a measured pressure. In some
embodiments, the membrane 103 may also be made of stiff ceramic
composition (i.e., Si3N4) having a high Young's modulus; in
such instances, the membrane 103 determines its deflection profile as a
function of ambient pressure. As illustrated in FIG. 1A, in some
embodiments, the membrane 103 may comprise a circular diaphragm of a
defined diameter with one or more electrical contacts 107 included in the
diaphragm. Membrane 103 may formed as a circular diaphragm, as the
circular diaphragm is a robust shape against a large stress gradient;
however, other shapes for the diaphragm comprising the membrane 103, such
as a hexagonal, square, or rectangular shape, may be used when creating
the membrane 103. Both the membrane 103 and the location of the one or
more electrical contacts 109 within the membrane 103 may be designed to
operate within a defined pressure range and designed to respond to one or
more pressure thresholds.

[0029] For example, when the membrane 103 comprises a circular diaphragm,
the perpendicular deflection (ω) of the circular membrane 103
within the cavity 113 may be directly related to a measured ambient
pressure (P):

ω(P)∝kP

[0030] Where k is a defined constant at the time of manufacture. For a
given radius (R) of the membrane 103, the expected deflection (WD) may be
calculated according to the equation:

[0031] Where r is the distance from the edge of the membrane 103 to the
deflection point (e.g., position of the electrical contact 107), ν is
the Poisson ratio, E is the Young's modulus, and h is the thickness of
the membrane 103. This formula may be used, for example, to determine the
expected deflection of the membrane 103 in response to a measured ambient
pressure when there is no internal stress present within the pressure
sensor 100. As both the Poisson ratio and the Young's modulus are based
on the properties of the material of the membrane 103 and on the method
of creating the membrane 103, the membrane 103 may be designed to operate
to react for a defined pressure range through choice of materials and
choice of manufacturing methods. Using this calculation, the electrical
contact 109 may be positioned (i.e., solving for r) so that the expected
deflection ωD is equal to the height of the cavity 113 at
defined pressure P. When the expected deflection is equal to the height
of the cavity 113, the electrical contact 109 may make galvanic contact
with the actuation signal path 107 on the opposite side of the cavity and
current may flow.

[0032] In some embodiments, there may be a significant amount of internal
stress within the pressure sensor 100. In such instances, the membrane
103 may become stiffer due to internal tension and, as a result, higher
pressures may be necessary to deflect the membrane 103 the same distance
within the cavity 113. The extra pressure required to exert on the
membrane 103 may be equal to the internal tension of the membrane. This
internal tension (σ) may be defined as:

σ ≈ 4 Eh 2 3 R 2 ( 1 - v 2 )
##EQU00002##

[0033] In some embodiments, the Timoshenko load-deflection model (based on
Timoshenko beam theory) may be used to determine the transition point
where the membrane 103 will deflect in response to a measured ambient
pressure. For example, when the membrane 103 is circular diaphragm and
subject to large deflections as a result of an applied, uniform external
pressure, the pressure sensor 100 may include a touch-point pressure
(Pt), which may be defined as the pressure at which the deflection
zoo is equal to the height of the cavity 113. When accounting for
stiffness in the membrane 103 due to bending and residual stress, while
also accounting for stiffness in the membrane 103 due to non-linear
stretching (e.g., a result of large deflections), the pressure may
directly affect the touch-point deflection (ω0) of the
membrane 103:

[0034] Where h is the thickness of the membrane 103, α is the radius
of the membrane 103, σ0 is the residual stress, D is the
flexural rigidity, and α is the Poisson ratio-dependent empirical
parameter. In some embodiments, the above equation may be used to
determine the touch-point pressure for the center of the membrane 103
when the membrane 103 comprises a circular diaphragm. In such instances,
the pressure sensor may be designed such that the electrical contact 109
may is positioned in the center of the membrane, at least one portion of
the signal path is positioned to make contact with the electrical contact
109 when the membrane 103 deflects, and the radius of the membrane 103
may set so that the pressure sensor 101 operates for a designated
touch-point pressure. In alternative embodiments, the applicable pressure
range may also be adjusted by modifying the thickness of the membrane
102, the height of the cavity 113, and the internal stress of the
membrane 103.

[0035] Cavity 113 between the membrane 103 and the substrate 105 may be
created through a deposit and removal of a sacrificial layer during
manufacture, with one or more physical vapor deposition (PVD) metallic
plugs hermetically sealing the cavity 113 from the outside environment.
In some embodiments, the cavity 113 may comprise a sealed vacuum. Cavity
113 may be designed to have a defined gap height between the one or more
electrical contacts 109 in the membrane 103 and a portion of the signal
path 107 on the substrate 105. In such instances, the gap height of the
cavity 113 may be chosen so that at a touch-point pressure, the
electrical contact 109 makes contact with a portion of the signal path
107 due to a deflection of the membrane 103 that is equal to that of the
gap height of the cavity 113.

[0036] FIGS. 1D-1F illustrate another exemplary pressure sensor 100. In
addition to the components 103-120 shown in FIGS. 1A-1C, the pressure
sensor in FIGS. 1D-1F also include an actuation electrode layer 101.
Pressure sensor may use the at least one actuation electrode layer 101 to
form a pressure-actuated switch. In such embodiments, the
pressure-actuated switch may be an electrostatic, microelectromechanical
systems (MEMS) switch that may be manufactured using MEMS techniques,
which are well known to one skilled in the art. Actuation electrode layer
101 may comprise one or more electrical conductors that may respond to an
electrical current by applying pressure on the membrane 103. In some
embodiments, the actuation electrode layer 101 may be made from
conductive materials, such as metals, metal alloys, and metal compounds,
such as metal nitrides, metal carbides, and metal silicides. In some
embodiments, the actuation electrodes 101 may be deposited with the
electrical contact 109 and/or signal path 107 and may therefore make
galvanic contact with one or more of these components.

[0037] In some embodiments, a second actuation electrode layer 101 may
also be included on the substrate 105. As illustrated in FIGS. 1E-1F, the
actuation electrode layer 101 on the substrate may be deposited on the
same layer as that of the signal path 107. In some embodiments, the
actuation electrodes 101 may create an electrical field within the cavity
113. This may be done, for example, through the use of a bias voltage,
illustrated in FIG. 1E as a bias voltage source, that is connected to
both actuation electrode layers 101. In such instances, the actuation
electrode layers 101 may act as a capacitor with an electrical field
through the gap comprising the cavity 113. The electrical field may then
exert a pressure similar to the ambient pressure measured by the pressure
sensor 100. In such instances, the first and second actuation electrodes
101 may then cause the membrane 103 to deflect through the cavity 113.

[0038] When the actuation electrode layers 101 cause the electrical
contact 109 to make galvanic contact with at least a portion of the
signal path 107, the current flow through the signal path may be a
different electrical circuit than the circuit formed by the bias voltage
131 and the actuation electrode layers 101. The actuation electrode
circuit may therefore trigger the electrical circuit that includes the
signal path 107. This may be done, for example, to calibrate and test the
pressure switch, as well as to adjust for any drift in the signal. For
example, in FIG. 1c, galvanic contact between the electrical contact 109
and the signal path 107 may allow a non-zero current flow. The current
flow may trigger an alarm. A user may activate the bias voltage in order
to determine whether the alarm is functioning correctly.

[0039] In other embodiments, the actuation electrode circuit may be
measured to, for example, determine the ambient pressure measured by the
membrane 103. This may be done, for example, by measuring the capacitance
between the two actuation electrode layers 101. As the size of the
actuation electrode layers 101 is known, the capacitance may be directly
proportional to the current gap height of the cavity, which has an
inverse relationship with the ambient pressure. From this measured value,
the ambient pressure may be calculated. In some embodiments, the measured
pressure may be saved in a memory or read-out on a connected display.

[0040] In some embodiments, pressure may rise within the cavity 113 after
the initial manufacture. This may occur, for example, when the pressure
sensor 100 is exposed to harsh environments, which may, for example,
result in hydrogen diffusion into the cavity from the outside environment
do to H.sup.+ generation and recombination with electrons at the opposite
actuation electrode 101. Similarly, the pressure of within the cavity 113
may rise due to hydrogen effusion from the silicon nitride-capping
membrane. In response, a high-density, nitrogen-rich silicon nitride film
may be used when manufacturing the pressure sensor 100 to alleviate such
occurrences from arising.

[0041] In addition, potential drifts in pressure may be mitigated through
an internal calibration of the pressure sensor 100, which may determine
whether the pressure sensor 100 needs to be adjusted or replaced. When
the ambient pressure is known, the capacitance may be measured between
the actuation electrode layers 101. From this measurement, the actual
deflection profile of the pressure sensor 100 may be compared to the
theoretical deflection profile of the pressure sensor 100. In some
embodiments, this may come in the form of calibration data that may be
saved in a memory component. Similarly, at a defined bias voltage on the
actuation electrodes 101, the membrane 103 may be pulled into collapse
(such a point may be accurately determined using the electrical contacts
109). The theoretical bias voltage may then be calculated for the
expected collapse of the membrane 103. These theoretical values may be
compared to the actual voltage of the collapse and may be used to
calculate the offset of the switch 100.

[0042] For both manual calibration and for switch adjustment, the pressure
sensor 100 may have the actuation electrode circuit deflect the membrane
103 using an applied electrical field. The bias voltage used to deflect
the membrane 103 may increase until the membrane 103 experiences a
touch-point pressure and the electrical contact 109 connects with the
signal path 107. The measured touch-point pressure may then be compared
with the initial touch-point pressure or theoretical touch point
pressure, which may be saved in a memory component. In some embodiments,
a specific bias voltage may be applied to set the deflection of the
membrane 103 to account for any differences between the actual and
theoretical deflection points in the membrane 103.

[0043] In some embodiments, a second sensor comprising a second membrane
(not shown) may be used in addition to the first membrane 103 to, for
example, mitigate adverse effects of temperature on the calculated
touch-point pressure. In such instances, the second membrane may not have
any actuation electrodes 101 attached to it, but the second membrane may
include a contact dimple. Though the second membrane will not be
actuated, the second membrane may have a smaller temperature dependence
than the first membrane 103 attached to the actuation electrodes 101;
this may be due to a lower thermal expansion coefficient. The two
switches 100 may be placed in series so that current would only flow if
both switches 100 were open or, alternatively, if both switches were
closed. In alternative embodiments, when a switch 100 is closed due to
thermal expansion but before the touch-point pressure threshold, the
second sensor may be activated to validate the pressure reading.

[0044] FIGS. 1G-1I illustrate another exemplary pressure sensor using an
exemplary electrode layer. Similar to the pressure sensor 100 of FIGS.
1D-1F, the top electrode layer 101 in FIGS. 1G-1I comprise two separate
portions. As illustrated in FIG. 1H, the actuation electrode portions may
not be physically connected, but the portions may be electrically
connected through the actuation electrode circuit to the bias voltage
131.

[0045] FIGS. 2A-2C illustrate another exemplary pressure sensor that
includes a signal path through the membrane. Pressure sensor 200 similar
to the pressure sensor 100 of FIGS. 1A-1I and includes similar components
201-233. However, the signal path 207 and the electrical contacts 209 may
be configured in a different manner than in the pressure sensor 100. For
example, as shown in FIGS. 2A-2C, the electrical contact 209 may also
include a portion of the signal path. In the illustrative embodiment, for
example, the electrical contact 209 includes an interconnect that
comprises only of one dimple. The interconnect may only require one
dimple in this instance, as the electrical contact includes a portion of
the signal path traversing on the membrane 203. As a result, when the
electrical contact 209 makes contact with the portion of the signal path
on the substrate 205, the current flows through the bottom portion of the
signal path and continues through the electrical contact 209, traversing
by the membrane 203. While the illustrative embodiment shows the signal
path 207 traverse above the membrane 203, various other embodiments may
have the signal path 207 connected to the membrane within the cavity 213.

[0046] FIGS. 2D-2F illustrate another exemplary pressure sensor that
includes a signal path through the membrane. Similar to the pressure
sensor 200 in FIGS. 2A-2C, the pressure sensor 200 of FIGS. 2D-2F
includes an electrical contact 209 with a signal path 207 connected to
the membrane 203. FIGS. 2F illustrates, however, that the signal path 207
connected to the substrate includes the interconnect with at least one
dimple. The interconnect in the bottom portion of the signal path 207 may
act in a similar manner as the interconnect that may be included in the
electrical contact 209.

[0047] FIGS. 2G-2I illustrate another exemplary pressure sensor and
pressure-actuated switch using an actuation electrode layer with an
electrical contact. Pressure sensor 200 in FIGS. 2G-2I is similar to
pressure sensor 200 in FIGS. 2A-2F, as it includes a signal path
traversing from the substrate 205 to the membrane 203. Pressure sensor
200 in FIGS. 2G-2I also includes actuation electrode layers 201 on both
the substrate and the bottom side of the membrane 203. In the
illustrative embodiment, the electrical contact 209 may be included in
both of the actuation electrode layers 201. In such instances, the
actuation electrodes may not be isolated from the signal path; rather,
the actuation electrode layers 201 may include both the signal path 207
and electrical contacts 209. As shown in FIG. 2I, when the actuation
electrode layers 201 make contact at a defined pressure, each of the
electrical contacts 209 make contact with each other, with the signal
path traversing from the substrate 205 to the membrane 203.

[0048] FIGS. 3A-3C illustrate another exemplary pressure sensor that
includes multiple electrical contacts. Pressure sensor 300 may be similar
to the pressure sensor 100, 200, with similar components 301-333.
However, as illustrated in FIGS. 3A-3C, the electrical contact 309 may
include more than one interconnect, which each interconnect located at
different distances away from the edge of the membrane 303. In such
instances, a first interconnect may make contact with the signal path 307
located on the substrate 305 at a first defined touch-point pressure,
while a second interconnect may make contact with the signal path 307 at
a second defined touch-point pressure.

[0049] In the illustrative embodiment, for example, the first interconnect
makes contact with the signal path 307 at the first defined touch-point
pressure, while a gap still remains in the cavity 313 between the second
interconnect and another portion of the signal path 307. In this
embodiment, one portion of an electrical circuit may be closed while
another remains open. This may result in an electrical signal passing
through the first portion of the signal path 307 and the electrical
contact 309 without passing through the second portion of the signal path
307. The signal may therefore traverse through the signal path 307
connected to the membrane 303. At a second defined touch-point pressure,
the second interconnect may make contact with the second portion of the
signal path 307, which may result in the electrical signal passing
through the second interconnect and the second portion of the signal path
307.

[0050] In some embodiments, the external electrical circuit connected to
the signal path 307 may behave differently based on the number of
contacts made. For example, the electrical signal may flow from the
signal path 307 to the electrical contact 309 the portion of the signal
path connected the membrane 303 as illustrated when only the first
interconnect makes contact at the first touch-point pressure. However,
when at the second touch-point pressure, the electrical signal may flow
through the second interconnect to the second portion of the signal path
307, similar to the current flow of the pressure sensor 100 of FIG.
1A-1L.

[0051] In some embodiments, when the first interconnect makes contact with
a portion of the signal path 307, a linear capacitance-pressure
relationship may result within the pressure sensor 300. Because the
capacitance scales with area, the electrical contacts may be placed at a
squared distance from the center of the membrane 303 to produce linear
responses to changes in pressure. In some embodiments, a system may
similarly use multiple pressure sensors 100 with different sized radii.
Because the touch-point pressure scales proportionally with 1/R4,
only small variations in distance in the membrane 303 are necessary to
enable reactions to a large ambient pressure range.

[0052] FIGS. 3D-3G illustrate another exemplary pressure sensor with a
lever. Pressure sensor 300 of FIGS. 3D-3G includes components 301-331,
333 similar to components 101-133 of the pressure sensor 100. Pressure
sensor 300 may also include a lever 332 which may be positioned in a
similar manner to that used to position the electrical contacts 109, 209.
In some embodiment, the lever 332 may be positioned on the substrate. In
alternative embodiments, the lever 332 may be positioned on the membrane
303 while remaining inside the cavity 313. As an example, in the
illustrative embodiment, the electrical contact 309 is positioned with an
interconnect in the membrane 303 and initially has galvanic contact with
the signal path 307 so that an electrical circuit is closed and an
electrical signal flows through the signal path 307 and the electrical
contact 309. As shown in FIG. 3g, when reaching a defined touch-point
pressure, the membrane 303 may deflect to the lever 332, pivoting the
membrane 303 on the lever 332 to break contact between the signal path
307 and the electrical contact 309. In some embodiments, the lever 332
may be used in conjunction with multiple electrical contacts 309, where
the pressure sensor 300 is used for inverse switching.

[0053]FIG. 4 illustrates a cross-section of an exemplary pressure sensor.
FIG. 4 illustrates an exemplary pressure sensor 400 that includes a
back-end-of-line (BEOL) layer 401, a substrate 403 including bottom
actuation electrodes and signal path 402, a cavity 404, a membrane 405
including an electrical contact 406 with an interconnect, top actuation
electrodes 408, and PVD plugs 411. As illustrated, the membrane 405 may
comprise a single layer that uses the PVD plugs 411 to seal the holes
used to form the cavity 404. PVD plugs 411 may be positioned in the
membrane 405 so that they are not located in portions of the membrane 405
that deflect in response to ambient pressure.

[0054] In some embodiments, the actuation electrodes 402, 408 may be made
of the same material as the electrical contact 406 and the PVD plug
material. In alternative embodiments, the electrical contact 406 may be
made from non-corrosive, non-oxidative materials (e.g., gold), alloys of
such materials, or alloys of noble materials with refractory materials
(e.g., titanium-tungsten, tantalum, tantalum nitride, etc.). In some
embodiments, the dimensions of the membrane 405 may be configured so that
they do not deflect under normal ambient pressures.

[0055] In some embodiments, a memory may be included with the pressure
sensor 400. This memory may be separate hardware or may be a function of
the pressure sensor 400 that activates at a defined pressure level. In
such instances, the pressure sensor 400 may be configured to permanently
close in response to a large current flow through the signal path 107.
Similarly, the pressure sensor may be configured to have the actuation
electrodes 101 keep the switch closed until the high voltage is
discharged from the switch 400.

[0056] In some embodiments, the pressure sensor 400 may be attached to a
power source, such as a battery, that may enable the pressure sensor 400
to make active responses, such as triggering an alarm when the switch is
closed. Similarly, some embodiments enable a user to manually close the
switch to test an alarm or to enable a pressure read-out even when the
ambient pressure is not at a touch-point pressure threshold. In such
instances, the signal path 107 may be closed through an additional
electrical contact 109 that may allow current flow when the ambient
pressure is not yet at a touch-point threshold.

[0057]FIG. 5 illustrates an exemplary flowchart for the pressure sensor
to trigger an alarm. Pressure sensor 100 may implement method 500, for
example, when the pressure sensor is an electrical switch or attached to
an electrical switch so that a touch-point pressure may trigger an
electrical current to flow through an external electrical circuit.

[0058] Method 500 may begin at step 501 and may continue to step 503,
where the membrane 103 of the pressure sensor is set to its initial
position. In some embodiments, the initial position is set so the
electrical contact 109 does not have contact with the signal path 107. In
alternative embodiments, the initial position is set so that the
electrical contact 109 has contact with the signal path; in such
instances, the pressure sensor 100 also includes a lever 331.

[0059] In step 505, the membrane 103 deflects in response to an ambient
pressure. Membrane 103 may deflect in the cavity 113 when the measured
ambient pressure is within the operating range of the pressure sensor
100. In step 507, the pressure sensor 507 may determine whether the
measured ambient pressure is equal to or exceeds the touch-point pressure
threshold. When the measured ambient pressure is below this threshold,
the pressure sensor 100 may remain in the same state as its initial
position and the method may return to step 505, where it waits for the
membrane 103 to further deflect. When the measured ambient pressure is
equal to or exceeds a touch-point pressure threshold, the state of
pressure sensor 100 changes, proceeding to step 509.

[0060] In step 509, it is determined whether there is contact between the
electrical contact 109 and the signal path 107. In some embodiments, the
change in state may initiate contact between the electrical contact 109
and the signal path 107. In such instances, the sensor 100 may proceed to
step 511, where current flow begins in the electrical circuit.
Alternatively, the change in state may break contact between the
electrical contact 109 and the signal path 107. In such instances, the
sensor 100 may proceed to step 513, where the current flow in the circuit
stops.

[0061] After steps 511 or 513, the sensor 100 may proceed to step 515,
where it is determined whether an alarm is triggered. For example, the
sensor 100 may be configured to trigger an alarm when the state of the
sensor 100 is changed from no current flow to a current flow. In such
instances, the sensor 100 may proceed from step 515 to 517, where the
alarm is actually triggered. This may comprise, for example, the
electrical circuit initiating a pressure readout. In some instances, the
electrical circuit may also initiate more active steps, such as opening a
vent or similar actions to actively change the ambient pressure of a
system. After step 517 or in instances when an alarm is not triggered,
method 500 may end at step 519.

[0062] FIGS. 6A-6L illustrate an exemplary method for fabricating a
pressure sensor. A manufacturer may implement the layering process
illustrated in FIGS. 6A-6L to produce a sensor similar to the pressure
sensor 100, 400 of FIGS. 1A-1C and 4, respectively.

[0063]FIG. 6A illustrates an exemplary CMOS substrate 600 comprising
back-end-of-line (BEOL) layer 601, and a substrate layer 603 that
includes, for example, a Physical Vapor Deposited (PVD) aluminum layer
605 and Chemical Vapor Deposited (CVD) tungsten plugs 607. In some
embodiments, the substrate layer 603 may be included in the BEOL layer
601. BEOL layer 601 and the substrate layer 603 may also include copper
interconnect lines and vias embedded in a tantalum/tantalum nitride
diffusion barrier layer. BEOL layer 601 may include, for example, up to 5
layers of metal. CMOS substrate 600 may then include an oxide (for
example, silicon oxide) on top of the BEOL layer. To include the aluminum
layer 605, holes may be used to contact the layer, while a CVD plugs 607
comprising of a metal such as tungsten may be used to fill the holes
after the aluminum layer is set.

[0064]FIG. 6B illustrates the deposition of the bottom electrode and
contact metal layer 609. In some embodiments, the bottom electrode and
contact metal layer 609 may include the actuation electrodes 101, signal
path 107, and/or electrical contact 109 including an interconnect with
one or more dimples. When the layer 609 includes the electrical contact
109 including an interconnect with one or more dimples, the electrical
contact 109 may be made of a noble metal (e.g., Pt, Pd, Au, Ag, Rh, Ir,
Ru, Os) in order to avoid oxidation and to minimize contact resistance.
Similarly, the electrical contact 109 may also be made of an alloy of
noble metals or an alloy of a noble metal with a transition metal in the
series of: Ni, Cr, Mo, W, Cu, Al, Ti, Zr, Hf, V, Nb, Ta, or Co.

[0065] In some embodiments, a combination of metals may be used to apply
the layer 609. For example, when apply the layer 609 using physical vapor
deposition (PVD), titanium may be used as an adhesion layer, while
platinum may be placed on the adhesion layer. In some embodiments, a mask
may be used to set the patterning of the layer 609. Continuing with the
Ti/Pt example, the Pt layer may be set using ion-beam etching that uses a
metallic hard mask, such as Al or Mo.

[0066]FIG. 6C illustrates the deposition of a protection layer 611 over
the bottom electrode and contact metal layer 609. In some embodiments,
the protection layer 611 may not be added; this may occur when the
sacrificial layer 613 and the bottom electrode and contact metal layer
609 do not interact and may be removed selectively to each other.
Protection layer 611 may comprise of a plasma-enhanced chemical vapor
deposition (PECVD) silicon nitride, silicon carbide, or silicon oxide (in
some embodiments, tetraethyl orthosilicate [TEOS]) layer. Protection
layer 611 may be very thin to improve the overall sensitivity of the
switch 100. In some embodiments, the protection layer 611 may be annealed
to densify the layer 611. As illustrated, asecond mask may be used in
some embodiments to pattern the protection layer 611 in order to allow an
opening for the contact dimple when included in the bottom electrode and
contact layer 609.

[0067]FIG. 6D illustrates the deposition of the sacrificial layer 613
over the protection layer 611 and/or bottom electrode and dimple metal
layer 609. The size of the sacrificial layer 613 may directly determine
the gap height of the cavity 113 of the switch 100 once manufactured.
Sacrificial layer 613 may also determine the sensitivity and operating
pressure range of the switch 100. Sacrificial layer 613 may be made of a
material such as aluminum, molybdenum, titanium, tungsten, or a similar
metal. In some embodiments, the sacrificial layer 613 may also be made of
a dielectric material, such as silicon oxide, as long as the contact
metal layer 609, protection layer 611, the membrane layer 614, and the
membrane capping layer 619 are not removed during the sacrificial etch.
As shown in FIG. 6D, some embodiments also include an intermediate
stopping layer. This may be used in some instances in lieu of the bottom
membrane layer 614. The intermediate stopping layer may be made of
aluminum oxide or similar material, or of a dielectric material. In some
embodiments, a mask may be used to position the sacrificial layer 613 and
the intermediate stopping layer. The location of the intermediate
stopping layer may in some embodiments, determine the dimple height and
therefore the touch-point pressure of the electrical contact 109.

[0068]FIG. 6E illustrates the deposition of the bottom membrane layer 614
over the sacrificial layer 613. As stated above in relation to the
membrane 103, the membrane layer 614 may be made of a thin PECVD silicon
nitride layer or a layer of similar material such as PECVD silicon
carbide that may deflect in response to a defined ambient pressure range.
Bottom membrane layer 614 may be annealed in order to densify the layer.
As illustrated in FIG. 6E, a mask may be used to pattern the bottom
membrane layer 614 so that, when etched (through, for example, dry
etching), the dimple is open for contact when the sacrificial layer 613
and intermediate stopping layer are removed.

[0069]FIG. 6F illustrates the etching of the bottom membrane layer 614.
As illustrated, a dry etch may make a contact 615 for the top electrode.
FIG. 6G illustrates the deposition of the top electrode layer 617 over
the bottom membrane layer 614. Top electrode layer 617 may be made of the
same material as the bottom electrode and dimple metal layer 609. Top
electrode layer 609 may be thin to enable high overall sensitivity for
the switch 100. In some embodiments, an Ar plasma may be used to clean
the surface of the contact 615 prior to the deposition of the top
electrode layer 617 to enable a good contact between the bottom electrode
layer 609 and the top electrode layer 617. In some embodiments, a hard
metallic (e.g., Al or Mo) mask may be used during ion-beam etching to
pattern the top electrode layer 617.

[0070] FIG. 6H illustrates the deposition of the capping layer 619.
Capping layer 619 may be a thick layer of PECVD silicon nitride; the
diameter, thickness, and internal stress of the capping layer 619 may
determine the rigidity of the membrane 103. The stress of the capping
layer 619 may be configured through the choice of deposition methods. For
example, in the case of PECVD silicon nitride, the silane (SiH4) or
ammonia (NH3) flow rates, plasma power, or deposition temperature
(e.g., 400'C) may change the stress of the membrane 103. In some
embodiments, the capping layer 619 may be annealed; for example, the
capping layer 619 may be furnace-annealed at 405'C., which may then take
a number of hours to stabilize and densify, while also removing excessive
hydrogen from the membrane 103. In some embodiments, the capping layer
619 may be PECVD silicon dioxide or PECVD silicon carbide.

[0071] FIG. 6I illustrates the patterning of sacrificial holes in the
membrane layers 614, 619. A dry etch on the membrane layers 614, 619 may
create contact holes 631, 635 and a sacrificial etch hole 633, stopping
at the bottom electrode layer 609 and the sacrificial layer 621,
respectively. Once the etching of holes 631-635 occurs, the sacrificial
layer 621 may be removed using a PS etch (e.g.,
H3PO4+HNO3), the sacrificial layer being Al, Mo, or an
ammonia-hydrogen-peroxide etch (e.g., NH4OH+H2O2), the
sacrificial layer being Ti or W. In some embodiments, an isopropyl
alcohol (IPA) drying step may occur after the removal step. This may be
done when the membrane 103 has a large diameter. Alternatively, an extra
mask of anti-sticking bumps may be applied after the deposition of the
sacrificial layer 621. In some embodiments, the sacrificial layer 621 may
be a silicon dioxide and may be removed using a dry etch (for example, an
HF vapor). In some embodiments, an annealing step (e.g. furnace
annealing) may be done to remove water from the cavity 113 form by the
removal of the sacrificial layer 621 and to remove excess hydrogen from
the membrane layers 614, 619.

[0072] FIG. 6J illustrates the deposition of PVD layer 625 over the
capping layer 619. As stated above in relation to PVD plugs 411, the PVD
layer 619 may be made from aluminum, titanium, titanium nitride or
similar material and may be used to plug the cavity 623 and to form the
bond pads of the pressure sensor 100. In some embodiments, a "hot" PVD
aluminum (e.g., deposition at 350° C.) flow is used to create a
"reflow" into the etch holes 631-635. This may seal the etch holes
631-635 without using a seam. The closure of the sacrificial etch hole
633 may create a vacuum-sealed cavity 623 at the PVD base pressure. In
some embodiments, the pressure in the cavity 623 may be a non-zero
pressure, having a pressure below the ambient pressure measured by the
membrane 103 such that it may deflect into the cavity 113. For example,
if the pressure sensor 100 is designed to operate for a range of 300-500
mbar, the pressure in the cavity 623 may be below 200 mbar.

[0073]FIG. 6K illustrates the patterning of the PVD layer 625. A mask may
be used to pattern the PVD layer 625 to create the PVD plug 626 and bond
pads 624, 628. In some embodiments, the PVD layer 625 may be removed from
the capping layer 619 using a mask and wet or dry etching. In some
embodiments, the membrane 103 may deflect slightly in response to the
ambient pressure after the removal of the PVD layer 625. This may be due
to a vacuum or low pressure inside the cavity 623.

[0074] FIG. 6L illustrates the deposition of passivation layer 627 on the
capping layer 625, PVD plug 626, and bond pads 624, 628. Passivation
layer 627 may be made of the same material as the membrane layers 611,
614, 619. A mask may be used to pattern the passivation layer so that the
bond pads 624, 628 remain exposed. In some embodiments, an annealing step
at, for example, 450° C. may take place after the deposition of
the passivation layer 627 to densify the layer.

[0075] It should be apparent from the foregoing description that various
exemplary embodiments of the invention may be implemented in hardware
and/or firmware. Furthermore, various exemplary embodiments may be
implemented as instructions stored on a tangible machine-readable storage
medium, which may be read and executed by at least one processor to
perform the operations described in detail herein. A tangible
machine-readable storage medium may include any mechanism for storing
information in a form readable by a machine, such as a personal or laptop
computer, a server, or other computing device. Thus, a tangible
machine-readable storage medium may include read-only memory (ROM),
random-access memory (RAM), magnetic disk storage media, optical storage
media, flash-memory devices, and similar storage media.

[0076] It should be appreciated by those skilled in the art that any block
diagrams herein represent conceptual views of illustrative circuitry
embodying the principals of the invention. Similarly, it will be
appreciated that any flow charts, flow diagrams, state transition
diagrams, pseudo code, and the like represent various processes which may
be substantially represented in machine readable media and so executed by
a computer or processor, whether or not such computer or processor is
explicitly shown.

[0077] Although the various exemplary embodiments have been described in
detail with particular reference to certain exemplary aspects thereof, it
should be understood that the invention is capable of other embodiments
and its details are capable of modifications in various obvious respects.
As is readily apparent to those skilled in the art, variations and
modifications can be affected while remaining within the spirit and scope
of the invention. Accordingly, the foregoing disclosure, description, and
figures are for illustrative purposes only and do not in any way limit
the invention, which is defined only by the claims.